U.S. patent application number 16/266459 was filed with the patent office on 2019-10-03 for strut light system with integrated light source.
The applicant listed for this patent is Walthill Opportunities, L.L.C.. Invention is credited to Benjamin S. Arriola, William Todd Crandell.
Application Number | 20190301713 16/266459 |
Document ID | / |
Family ID | 63037595 |
Filed Date | 2019-10-03 |
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United States Patent
Application |
20190301713 |
Kind Code |
A1 |
Crandell; William Todd ; et
al. |
October 3, 2019 |
STRUT LIGHT SYSTEM WITH INTEGRATED LIGHT SOURCE
Abstract
A ceiling grid system formed of struts has a plurality of
elongate insert light units. The grid system suspended from the
ceiling and comprising a multiplicity of steel elongate channels
(struts) arranged in the grid. The channels having a downwardly
directed U-shape and defining an opening and an open channel
interior, the channel having opposing J-shaped wall portions, each
wall portion with an inwardly directed curved lip portion defining
a gap width therebetween the two wall portions. The elongate insert
light units seated within one of the steel elongate channels, each
insert light unit having an elongate body with a light emitting
side, each insert light unit comprising a housing, and a strip of
light emitting diodes, and a transmission portion at the light
emitting side, the body retained in the interior of the channel,
each light unit removable and replaceable with the respective
channel.
Inventors: |
Crandell; William Todd;
(Minnetonka, MN) ; Arriola; Benjamin S.;
(Deephaven, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Walthill Opportunities, L.L.C. |
St. Louis Park |
MN |
US |
|
|
Family ID: |
63037595 |
Appl. No.: |
16/266459 |
Filed: |
February 4, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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15892711 |
Feb 9, 2018 |
10197254 |
|
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16266459 |
|
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62457113 |
Feb 9, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F21K 9/00 20130101; F21S
4/28 20160101; F21S 8/061 20130101; F21Y 2103/10 20160801; F21V
21/025 20130101; F21V 21/34 20130101; F21V 17/162 20130101; F21V
31/005 20130101; F21V 21/005 20130101; F21V 21/03 20130101; F21V
17/04 20130101; F21V 29/83 20150115; F21V 23/002 20130101; F21V
23/02 20130101; F21Y 2115/10 20160801; F21V 23/008 20130101 |
International
Class: |
F21V 21/34 20060101
F21V021/34; F21V 21/005 20060101 F21V021/005; F21V 17/04 20060101
F21V017/04; F21K 9/00 20060101 F21K009/00; F21S 8/06 20060101
F21S008/06; F21V 23/02 20060101 F21V023/02; F21V 23/00 20060101
F21V023/00; F21V 21/03 20060101 F21V021/03; F21V 17/16 20060101
F21V017/16; F21S 4/28 20060101 F21S004/28; F21V 29/83 20060101
F21V029/83; F21V 21/02 20060101 F21V021/02 |
Claims
1. A combination ceiling channel system and a plurality of elongate
insert light units, the channel system comprising a plurality of
elongate channels, the channel system suspended below and spaced
from a ceiling, each of the plurality of the channels defining an
opening and an open channel interior, the channel having opposing
walls, each wall with an inwardly directed lip portion defining a
gap width therebetween; each of the elongate insert light units
seated within one of the plurality of elongate channels, each
insert light unit having an elongate body with a light emitting
side, each insert light unit comprising a strip of light emitting
diodes for generating light from the light emitting side, the body
retained in the interior of the channel, each light unit removable
and replaceable with the respective channel.
2. The combination of claim 1 wherein the body of each light unit
is rectilinear in shape and has a portion with a light unit width
that is greater than the gap width of the respective elongate
channel.
3. The combination of claim 2 wherein each light unit is entirely
contained within the interior of the respective elongate
channel.
4. The combination of any of claim 1, further comprising a spring
retention member for retaining each light unit in the respective
elongate channel.
5. The combination of claim 4 wherein the spring member comprises a
coiled spring and is positioned between a surface of the light unit
opposite the light emitting side and engages an inside facing
surface of a wall of the U-shaped channel opposite the channel
opening.
6. The combination of claim 1, wherein the grid system further
comprises a plurality of metal boxes attached to a plurality of the
multiplicity of elongate channels, and the combination further
comprises a plurality of power units, each power unit positioned in
a metal box and electrically connected to one of the plurality of
light units.
7. (canceled)
8. The combination of claim 1 wherein each light unit has a light
unit width that is greater than the gap width.
9. The combination of claim 1, wherein each light unit is removable
and replaceable manually without using hand tools.
10. The combination of claim 9 wherein the light transmission
portion of each light unit is position inwardly from the lips of
the opposing walls.
11. The combination of claims 1, wherein the light transmission
portion of each light unit is positioned outwardly from the lips of
the opposing walls and wherein the respective strip of light
emitting diodes is positioned within the interior of the respective
elongate channel.
12-14. (canceled)
15. A combination elongate channel and an elongate insert light
unit, the elongate channel defining an opening and an open channel
interior, the channel having opposing walls, each wall with an
inwardly directed lip portion defining a gap width therebetween;
the insert light comprising an elongate body with a light emitting
side, each insert light unit comprising a strip of light emitting
diodes for radiating light from the light emitting side, the body
sized for insertion into and removal from the interior of the
channel without using tools, whereby when the channel is hung from
a ceiling light generated from the strip of light emitting diodes
is directed from the opening of the respective channel.
16. The combination of claim 15 wherein the body of the light unit
is rectilinear in shape and has a portion with a light unit width
that is greater than the gap width.
17-19. (canceled)
20. The combination of claim 15, further comprising a spring
retention member for retaining the light unit in the elongate
channel.
21. The combination of claim 15, the light unit seats within the
interior of the elongate channel and is retained therein by
gravity.
22. The combination of claim 20 wherein the spring member is a
coiled spring and is positioned between a surface of the light unit
opposite the light emitting side and engages an inside facing
surface of a wall of the elongate channel opposite the channel
opening.
23-24. (canceled)
25. A method of retrofitting a ceiling grid system with a plurality
of elongate insert light units, the grid system comprising a
plurality of elongate channels arranged in a grid, the grid
suspended below and spaced from a ceiling, a plurality of the
channels defining an opening and an open channel interior, the
channel having opposing walls, each wall with an inwardly directed
lip portion defining a gap width therebetween; and each of the
elongate insert light units sized to be seatable within one of the
elongate channels, each insert light unit having an elongate body
with a light emitting side, each insert light unit comprising a
plurality of light emitting diodes for directing light from the
light emitting side, the body sized to be retained in the interior
of the channel, each light unit removable and replaceable within a
respective channel; the method comprising insertion of each of the
body portions of the plurality of elongate insert light units
within the interior of respective channels of the plurality of
elongate channels.
26. The method of claim 25, further comprising placing each light
entirely within the interior of the elongate channel.
27. The method of claim 25, further comprising compressing a spring
member for retention of the light unit in the channel interior.
28. The method of claim 25, wherein the body of the light unit has
a width that is greater than the elongate channel gap width and the
method further comprises rotating the light unit in a first
direction before insertion into the channel and then rotating the
light unit in a second direction, opposite the first direction
after the body of the light unit is in the interior of the elongate
channel, and then seating the light unit on the curved lip
portions.
29. The method of claim 25, further comprising mounting a power
supply in a metal box connected to the grid system, connecting the
light unit electrically to the power supply.
30-69. (canceled)
Description
[0001] This application claims priority to U.S. Pat. No. 10,197,254
issuing Feb. 5, 2019, which claims priority to Provisional
Application No. 62/457,113, filed Feb. 9, 2017, the contents of
both being incorporated herein by reference in their entirety for
all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates to the general construction of
building systems internal mechanical support structure and the
general lighting in open ceiling areas of industrial and commercial
spaces that incorporate the building systems mechanical support
structure. More specifically, the present invention relates to the
design, installation and construction of a structural lighting
system that seamlessly integrates into the building support
structure commonly used in open ceiling spaces, generally comprised
of structural channel systems, that supports the building systems
mechanical, electrical and plumbing (MEP).
BACKGROUND OF THE INVENTION
[0003] Structural channel members, commonly known as strut channel,
are used ubiquitously in industrial and commercial spaces to
provide mechanical support for building mechanical, electrical, and
plumbing (MEP) as well as, communication cabling and other ceiling
mounted building system components. Examples of these structural
channel mechanical support systems include Unistrut.TM., Eaton
B-Line.TM. and other similar branded and unbranded systems. Often
structural channel systems are used in open ceiling structures in
back rooms, hallways and basement mechanical rooms as well as other
open ceiling areas of buildings. In these applications, the areas
containing structural channel systems have general lighting
supplied by a variety of non-specific lighting fixtures ranging
from simple A Lamp type fixtures to vapor tight linear fixtures as
well as many other common fixture forms. The most common fixtures
used for open ceiling lighting include track lighting with spot
lights, linear vapor tight fixtures and open linear fluorescent
strip fixtures commonly utilizing T12-T5 linear fluorescent tubes
and more recently, LED lighting sources.
[0004] The structural channel members or strut channel for these
areas are selected and specified to safely support specific
carrying loads for building system components. All mechanical loads
attached to the structural channels increase the sizing of the
structural members and associated mounting hardware. Any additional
light fixture structure suspended from the strut channel structure
is therefore included in these load calculations, thus reducing the
carrying capacity of the overall mechanical structure. Additional
load from light fixtures, electrical track light buss systems and
other supporting components, such as cabling or pendant mount
hardware, reduce the system mechanical load carrying capacity by
tens to hundreds of pounds per section and potentially thousands of
pounds over a full ceiling space. While the structural channels are
specified to carry these additional loads, additional structural
channel or larger, stronger structural members must be specified to
accommodate the addition of lighting system loads, thereby
increasing costs for materials, installation time, and incidental
project-related, schedule-driven costs and overhead.
[0005] Critical to the specifications of these spaces is head room
or clearance for fixed and moveable equipment such as furnaces,
boilers, server equipment, pumps or other common equipment found in
mechanical and electrical rooms, as well as physical room for
workers or occupants to work in or pass through an area. Hallways
in basements or industrial spaces are another common area where
insufficient head room for equipment and personnel can be an issue.
The head room in these spaces can be greatly reduced by the
addition of lighting fixtures. Architects and designers are forced
to adjust building layouts to move plumbing, electrical conduit,
HVAC ducting and other building mechanical, electrical and plumbing
system components to the corners of hallways, along the walls, or
into other areas in order to accommodate the design space necessary
for the lighting. Construction of mechanical, electrical and
plumbing systems must accommodate lighting fixtures and often
require routing of multiple parallel conduits, pipes or HVAC duct
work. These multiple parallel routing paths result in extra bends
in piping or conduit and faceting of sheet metal vents which are
extremely time consuming and expensive for electrical contractors
to install, negatively impacting project costs and schedules.
Engineers and designers are faced with significant design
challenges when determining routing for the mechanical and
electrical systems while still meeting building code requirements
for MEP routing, and lighting these spaces further negatively
effects project schedule and costs.
[0006] Where building system components cannot be moved to
accommodate the lighting fixture and still meet head space
requirements, light fixtures are placed higher up in the open
ceiling space resulting in significantly obstructed lighting with
either poor light levels and/or non-uniform lighting, with
significant shadowing from the building system components suspended
below the lighting fixtures. The obstructed lighting further leads
to building energy inefficiencies as higher-light level,
higher-energy consumption fixtures must be specified in order to
meet minimum floor level or working area light level
requirements.
[0007] Due to the complexity of MEP routing, the lighting fixtures
for the areas are often difficult to specify and are either left
unspecified or generically specified during the building design
process. The fixtures ultimately used are frequently not optimized
for headroom, lighting performance, energy consumption or
installation costs. Lighting fixtures used frequently provide
either ineffective lighting or excess lighting resulting in poor
lighting or inefficient energy designs. Insufficient uniform
lighting due to shadowing or obstructed light creates dark spaces
and the need for additional secondary or temporary lighting (I.e.
(i.e., utility lights, head lamps or flash lights), further leading
to building energy inefficiencies and increased operational
costs.
[0008] Lighting fixtures added to open ceiling space are frequently
painted or otherwise designed to conceal the fixture to minimize
the undesired aesthetic impact on the space. Particularly in open
ceiling designs, pendant and other fixture styles that hang down
from the ceiling are often painted to match the ceiling or
surrounding walls to try to prevent the fixture from breaking up
sightlines in a space. These approaches are generally a compromise
by the architect or designer and have minimal beneficial effect as
the fixture structure will still block visual sightlines, impact
daylighting effectiveness, and obstruct preferential views of
artwork, windows, signage, emergency exits, etc., as well as block
access to observe essential building electrical and mechanical
systems.
[0009] The Lighting fixtures added to any space inherently add cost
and time to install due to the need for additional hanging
structure and electrical components necessary for the fixtures.
Companies selling strut channel often provide elaborate and
expensive systems for mounting lighting fixtures and routing wiring
for power connection. Many of the solid-state lighting ("SSL")
fixtures used for better energy efficiency come with
additional--non-standard--mounting hardware or methods.
Installation time and costs are increased due to unfamiliarity with
mounting the fixture by the electrical contractor or due to the
need to source uncommon components necessary for mounting the light
fixtures. Even traditional light fixtures require additional
hangers and hardware not otherwise used by the Electrical or
Mechanical Contractor in normal assembly of the ceiling space.
Companies providing strut channel frequently offer a vast array of
additional hangers and components for mounting suspended light
fixtures, routing wiring and making power connections; all of which
increase system weight, add cost and create aesthetic
tradeoffs.
[0010] SSL lighting fixtures and lighting fixtures in general used
in open ceiling spaces tend to be inherently fragile in nature.
Lens or optics are typically exposed, thin, brittle plastic and
housings manufactured from thin sheet metal, plastic or aluminum
extrusions that may be easily bent or damaged when handled by
workers using tools and mechanical components when installing or
repairing building mechanical or electrical systems, often routed
in ceiling adjacent to or above the lighting fixtures. Mechanical
damage to light fixtures, particularly in mechanical rooms and
other industrial spaces is common, requiring full fixture or lens
replacement to repair the lighting fixture and increasing fixture
costs or schedule delays on projects or increasing maintenance
costs for facilities.
[0011] Lighting fixtures in open ceiling food preparation areas
carry a separate set of requirements in addition to having head
space and fixture locations requirements, fixture access for
cleaning is critical. Lighting fixtures added to support channels
and frame members within food preparation spaces inherently block
access for cleaning as well as create potential pockets and dead
spaces above the lighting fixtures or between lighting and support
structures.
[0012] Generally speaking, SSL technology has been adopted to many
traditional fixtures to make improvements in energy efficiency of
light fixtures used in open ceiling space applications. SSL
solutions have been developed extensively for vapor tight and
linear fluorescent type fixtures, again for the benefit of energy
savings. SSL technology has not been as effectively applied to the
problems with traditional fixtures as stated above relating to head
space, loading, aesthetics and sightline obstruction and many of
the solutions still use traditional or more complicated mounting
systems, again adding extra costs and assembly time.
[0013] There is therefore, a general need for a lighting system
providing the utility of meeting both the structural requirements
of the building mechanical, electrical and plumbing systems
structural support as well as meeting the general lighting
requirements of the intended spaces. This need is particularly
found in industrial and mechanical spaces with open ceiling
construction and in open ceiling construction with low ceilings
with supporting building mechanical, electrical and plumbing
systems. Further, there is a general need for a lighting system
with the added benefits of meeting lighting design, space
aesthetics, performance and efficiency requirements intended by
designers and architects without the negative tradeoffs of
currently available and traditional lighting systems.
SUMMARY OF THE DISCLOSURE
[0014] Embodiments herein provide an SSL lighting system, light
units, fixture assemblies, retrofit methods, and assembly methods
associated with, or that replace, the structural channel structure
commonly used in industrial, retail and commercial open ceiling
applications. Embodiments of an SSL lighting fixture includes a
lighting circuit, housing, optics, sealing mechanism, drive
circuit, strut channel mechanical structure, and related electrical
connection and mounting hardware system.
[0015] The SSL lighting system, in certain embodiments, replaces
portions of existing open ceiling structural channel mechanical
support structures and eliminates the need for additional,
traditional mounted, recessed or pendant type lighting fixtures.
The SSL system includes one or more SSL lighting fixtures mounted
through traditional structural channel mounting approaches. The SSL
lighting system incorporates low voltage electrical power supplies,
wiring and electrical connections to power the SSL lighting
fixtures throughout the SSL system. The SSL lighting system, in
certain embodiments, installs directly into existing open ceiling
structural channel mechanical support structures and eliminates the
need for additional, traditional mounted, recessed or pendant type
lighting fixtures. The SSL lighting system includes one or more SSL
Light Unit 10 or subassemblies mounted through the structural
channel opening or open end without disruption to the traditional
mounting methods used with the structural channels. The SSL
lighting system, when installed either as an SSL light fixture
assembly or as a SSL light module subassembly kit in an open
ceiling structure, makes it possible to realize several benefits
over standard lighting fixture designs and structural channel
ceiling structures.
[0016] The SSL lighting fixture mechanical design includes one or
more SSL Light Subassemblies 20 and adds no appreciable additional
weight to the structural member due to addition of a light fixture
structure. The only additional weight required to consider for
loading calculations is the optimized minimal weight of the
subassembly light strip, heat sink and optics, thus optimizing the
structural loading available capacity of the structural member to
its absolute maximum for a structure including a ceiling mounted or
suspended lighting system.
[0017] This SSL lighting fixture mechanical and lighting circuitry
adds no additional height to the structural channel member. The SSL
lighting system achieves ideal lighting performance while
fully-contained within the mechanical structural elements. The
available space for headroom or mechanical, electrical or plumbing
system routing is therefore optimized to its absolute maximum for a
structural channel ceiling system with lighting.
[0018] The fixture mechanical construction allows lighting to be
positioned as required in the space (e.g., centered on a hallway)
for achieving efficient and effective lighting of the space
additionally, without any limitation to the placement or routing of
mechanical, electrical or plumbing system components due to
interference with the lighting system, thus effectively increasing
the available space for routing of mechanical, electrical or
plumbing system components. The SSL lighting system can be placed
below building system MEP and mechanical open ceiling structure,
thus minimizing the obstruction of the lighting from building MEP
components. Energy consumption and lighting performance are
optimized for the space and likewise not impacted negatively by the
routing design for mechanical, electrical and plumbing system
components.
[0019] This SSL lighting system maintains the aesthetics of the
open ceiling architectural design with no additional impact on the
visual sightlines, daylighting effectiveness or preferential views
of artwork, windows, exits or signage. Visual impact on gauges,
indicators and computer screens as well as other informative
building system devices is optimized to an absolute minimum for a
structural channel, open ceiling lighting system. Lighting
performance for viewing of gauges, indicators, computer screens and
other building system devices is also optimized due to elimination
of shadowing from mechanical, electrical or plumbing building
system components or associated mounting hardware.
[0020] The SSL lighting system provides a specified or unspecified
lighting option for Electrical, Mechanical and General Contractors,
as well as specifying Architects, that provides an optimized
lighting and energy saving solution for maintaining project budgets
and schedules, without sacrificing lighting performance, energy
consumption or safety. Light fixture installation time and cost is
minimized utilizing existing structural channel mounting hardware
with no additional hardware required beyond the hardware already
required for mounting of the structural channel.
[0021] This SSL Light Subassembly 20 is fully self-contained within
the common structural channel. The structural channel providing
features for mounting, as well as additional heat sinking if
required, for the SSL electrical circuit for effective operation.
The SSL light fixture subassembly and fixture structural channel
further provides full protection for the SSL electrical circuit and
optics assembly from mechanical, environmental or electrical
damage. The protection provided by the structural channel and
fixture design and mounting system eliminates the need to replace
damaged light fixture lenses or full fixtures damaged during
installation or maintenance of adjacent mechanical, electrical or
plumbing systems.
[0022] The SSL Fixture Subassembly (or module) includes the SSL
lighting, electrical, housing and optical system and accommodates
assembly of the SSL fixture subassembly within a novel structural
channel or common strut channel structural members with openings
allowing use in any strut channel ceiling structure. The SSL
fixture subassembly system circuit, electrical design and optics
design have been optimized within the lighting fixture subassembly,
within the mechanical constraints of the strut channel
configurations, and utilize mechanical mounting components allowing
for installation through open face or open end of or common strut
channel structures. Further enhancements and improvements of
lighting efficiency and optics efficiency of the mechanical,
electrical and optical light fixture can be achieved through
modification of the standard strut channel openings and spacing in
combination with electrical circuit and optics designs.
[0023] The electrical, housing and optical subassembly optimizes
lighting efficiency and effectiveness in a strut channel ceiling
structure by eliminating shadowing and dark areas resulting from
pendant mount or recessed lighting systems, optimizing coefficient
of utilization of the light fixture. Further, the fixture design
accommodates up lighting, side lighting and down lighting solutions
utilizing common strut channel construction and thereby reducing or
eliminating the need for and costs associated with secondary
lighting, such as additional wall mounted light fixtures, worker
head lamps, flashlights, or utility lights. Further, the optical
system provides optimized uniform lighting in narrow, wide or
batwing arrangements.
[0024] The SSL lighting fixture assembly can be constructed to
provide up, side or down lighting configurations, as well as
construction providing centered or offset SSL subassembly lighting
solutions. Offset SSL subassembly construction provides for
alternate aesthetic lighting design effects, as well as
optimization of routing designs for building system components. The
impact on routing spaces for a 10' W.times.8' H hallway resulted in
a 22-33% increase in available routing space by utilizing the SSL
light fixture assembly over traditional vapor tight or 2'.times.4'
fluorescent troffer light fixtures. A 144%-166% increase in
available routing space can be gained if the routing design
requires continuous adjacent routing of building system
components.
[0025] The impact on available vertical routing space for a
10'W.times.8'H hallway resulted in a 128% increase gained assuming
a 1' available routing space and a typical 6.75'' deep vapor tight
fixture. Alternate light fixture comparisons and ceiling height
constraints would provide differing results, however; in all
scenarios, the SSL light fixture assembly provides equal, or an
improved routing area. Routing volume (product of increased
horizontal routing and vertical routing spaces) further
demonstrates the improvement of routing space for building system
components as a result of using the SSL light assembly fixture.
[0026] The SSL light fixture assembly when installed in open
ceiling food preparation areas improves fixture access for cleaning
by eliminating blocked access from installed traditional light
fixtures. Further, the SSL Lighting Subassembly in one embodiment
can be adapted to include UV up lighting for germicidal sanitation
and cleansing. The SSL Light Subassembly 20 further includes full
seals and structure to withstand pressure washing required in
cleansing of food preparation areas.
[0027] The impact on pipe routing times and costs was estimated by
a certified electrician to be 12 hours on average for a bend pipe
application consisting of 9.times.90-degree double bends to route
around a space for a light fixture. By using embodiments herein,
the pipes, according to the certified electrician, could be routed
straight and the entire 12 hours of time would be the cost savings
and schedule time savings.
[0028] The SSL Light Subassembly 20 allows for the finished
assembly of the SSL Fixture Assembly to be completed in the field.
The mechanical and electrical assembly of the SSL lighting assembly
sealed in a manner which provides the necessary durability to
withstand the environments and field handling for field
installation into the strut channel. Installation into the strut
channel can be achieved through insertion through the open face of
the strut channel or insertion into an open end of the strut
channel and slid down the length into position. Features in the
housing and optic surface provide a protective element to prevent
lens damage during installation. The combined optic, LED electrical
circuit and heat sink and system of sealing the assembly provides a
lighting subassembly with an overall rigidity and strength required
for handling and field installation. Insertion and removal trials
were conducted with the SSL Light Subassemblies 20.
[0029] Early prototypes without the flat top surface, notched
endcaps, flat housing back surface and semi-circular inset corners
experienced repeated jamming of the retention spring plate and
subassembly within the strut channel opening and pocket. SSL Light
Subassembly 20 when inserted were found to be off-center resulting
in modified light output patterns or undesirable aesthetic results.
Retention spring plates placed in normal mounting orientation with
the plate positioned at the face of the opening also resulted in
jamming of the SSL Light Subassembly 20, retention spring plate and
strut channel pocket during installation. Installation via this
method resulted in greater than 70% jamming during installation.
Use of a spring plate for retention with the plate positioned to
align with the back surface of the SSL Light Subassembly 20
resulted in less than 20% jamming and jamming was less severe
(i.e., more easily corrected).
[0030] Testing was conducted of the optical alignment system within
the SSL Light Subassembly 20 assembled in a 15/8'' strut channel.
The subassembly placed first at a position consistent with the
endcaps with the removable tabs intact, still in place. The
resulting light output angle imaged at an approximately 90-degree
batwing pattern. Photo imaging of the test assembly shows the
reflected surface light on the opening vertical walls. Optical ray
tracing of the reflected light indicated that the majority of the
light was being pushed back into the batwing pattern with a small
percentage reflecting outside the 90-degree batwing pattern.
Further enhancements of the optical alignment system and strut
opening would optimize the reflected light pattern and increase the
assembly coefficient of utilization, placing more of the reflected
light output into the appropriate area of the 90-degree batwing
pattern. Similarly, addition of a baffled surface at the strut
opening vertical surface would act to reduce glare and absorb or
redirect the light back into the SSL Light Subassembly 20 to be
redirected into the 90-degree batwing pattern, or again reflected
back into the subassembly.
[0031] Repositioning of the optical alignment system, to a position
consistent with the removal of the endcap removable tabs, resulted
in a light output angle of approximately 120 degrees within a
batwing pattern. Photo imaging of the test assembly showed a
reduction of the reflected light on the strut opening vertical
walls; these results were confirmed with photometric simulation and
testing. Further refinement of the optical alignment system and
strut opening would optimize the batwing pattern to adjust for
LED-to-batwing lens position relative to strut opening features and
position.
[0032] Placement of a secondary optical component into the optical
alignment system, to produce a narrowing or asymmetric pattern to
achieve a narrowing of the batwing pattern or an asymmetric wall
washing effect were also conceived and tested. Further refinement
of these approaches within the optical alignment system are
required to optimize these patterns.
[0033] Light testing of the SSL Lighting Fixtures versus commonly
available fixtures within an industrial space demonstrated
performance gains in fixture coefficient of utilization, uniformity
of light levels and corresponding enhanced energy efficiencies.
Tests of a vapor fixture resulted in a 43% reduction in power
consumption with a corresponding 16% increase in light output from
the SSL Light Fixture. The corresponding improved fixture
coefficient of utilization in a 10' room with 8' ceilings was
greater than 30% improvement. Tests were performed to validate the
effective assembly of an SSL Lighting Subassembly into common strut
channel open continuous slot and open end, validating the ease of
installation, standard and custom fastening methods, subassembly
durability during assembly and subassembly alignment within the SSL
Fixture and System. Tests were conducted to demonstrate physical
durability testing and trials with the new and strut channel light
fixture versus traditional light fixtures, demonstrating excellent
results in durability and survivability when exposed to typical
mechanical handling and impact.
[0034] A feature and advantage of embodiments is a method of
installing an elongate light unit in an U-shaped channel with
inwardly turned edges at the channel opening, the channel opening
facing downwardly, the method comprising rotating the light unit so
that a lateral edge of the light unit is confronting the channel
opening, the thickness of the light unit being less that the width
of the channel opening, inserting the light unit into an open
interior of the channel the lateral edge first, rotating the light
unit 90 degrees when the light unit is in the open interior of the
channel whereby the horizontal width of the light unit is greater
than the width of the channel opening, whereby the light unit is
retained in the interior of the U-shaped channel.
[0035] Designs, descriptions and illustrations included in this
disclosure come from the experimental work and are representative
of certain embodiments of the present invention but are not limited
to these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1A End view of a structural (Strut) channel SSL Light
Fixture Assembly with SSL Light Subassembly.
[0037] FIG. 1B Section view of SSL Light Assembly with installed
SSL Light Subassembly.
[0038] FIG. 2 Exploded isometric view of SSL Light Fixture Assembly
and SSL Light Subassembly.
[0039] FIG. 3 Isometric view of installed strut channel grid system
with SSL Light Assembly and Mechanical, Electrical and Plumbing
(MEP) components.
[0040] FIG. 4 Isometric view of SSL Light Subassembly.
[0041] FIG. 5A SSL Light Subassembly with continuous SSL (LED)
Circuit construction and light output.
[0042] FIG. 5B SSL Light Subassembly with segmented SSL (LED)
Circuit construction and continuous or segmented light output.
[0043] FIG. 5C SSL Light Subassembly with individual spot SSL (LED)
Circuit construction and light output.
[0044] FIG. 6A SSL Light Assembly with segmented SSL Light
Subassembly installation and light output.
[0045] FIG. 6B SSL Light Assembly with continuous SSL Light
Subassembly installation and light output.
[0046] FIG. 7 SSL Light Subassembly--Detailed cross-section with
features.
[0047] FIG. 8 SSL Light Subassembly--Cross Section with Endcap
Detail (Alignment Notch, Removable Tab, Finger Grip features).
[0048] FIG. 9 SSL Light Subassembly--Cross Section with Extrusion
Housing Detail (Finger Grip, Lens Seal, Board Center, Semi-Circular
Lens Alignment and Seal features).
[0049] FIG. 10 SSL Light Subassembly--Cross Section with Extrusion
Housing Detail--Side and Top Thermal Convection Features.
[0050] FIG. 11A SSL Light Assembly--Section View Down Lighting Thru
Continuous Opening.
[0051] FIG. 11B SSL Light Assembly--Section View Up Lighting Thru
Continuous Opening.
[0052] FIG. 11C SSL Light Assembly--Section View Down Lighting Thru
Perforated Opening.
[0053] FIG. 11D SSL Light Assembly--Section View Up Lighting Thru
Perforated Opening.
[0054] FIG. 11E SSL Light Assembly--Section View Down/Side Lighting
Thru Continuous Opening.
[0055] FIG. 12A Optical control surfaces use of structural channel
opening to optimize light output pattern.
[0056] FIG. 12B Optical control surfaces at channel opening to
optimize light output pattern.
[0057] FIG. 13 Use of the optical alignment system to optimize the
light output angle.
[0058] FIG. 14 Light subassembly extended beyond strut channel
structure.
[0059] FIG. 15A Subassembly wiring system and method for remote
driver in a fixed standard J-Box installation with fittings.
[0060] FIG. 15B Subassembly wiring system and method for remote
longitudinal footprint LED driver in a strut channel raceway with
fittings.
[0061] FIG. 15C Subassembly wiring system and method of
installation for remote LED driver with wire harness and strut
channel fitting.
[0062] FIG. 16 SSL Light Subassembly--Exploded View Assembly
Drawing.
[0063] FIG. 17 Is a detailed perspective view of a connection to a
light unit.
[0064] FIG. 18 Is a detailed perspective view of a connection
between the housing an end cap.
[0065] FIG. 19 Is the connection of FIG. 18 from an opposite
view.
[0066] FIGS. 20-23 Are perspective views of quick connect plugs and
receptacles.
[0067] FIGS. 24-26 Are perspective views of an end unit.
DETAILED DESCRIPTION
[0068] Referring to FIGS. 1A-4, SSL Light Fixture Assembly 10
comprises of one or more SSL Lighting Subassemblies or elongate
insertable light unit 20, with an LED electrical circuit 201,
housing 202, endcaps 203, lens 204.1 and optics 204.2 with a system
for mounting, alignment and powering of the subassembly. The SSL
Light Fixture Assembly 10 may be either stand alone or part of a
larger ceiling grid system 30. The larger ceiling grid system 30
comprising a plurality of structural channels 101 suspended some
distance from a ceiling 302 or support beam via mechanical hardware
or cabling 304. The stand-alone SSL Light Fixture Assembly 10,
either stand alone or integrated as part of the larger ceiling grid
system 30, providing structural support for building system (MEP)
305 and other building system components.
[0069] The SSL Light Fixture Assembly 10, in embodiments includes
an outer mechanical structure configured as a U-shaped channel 101
designed to provide an open interior 102 to contain the light unit
20 and a channel or light unit opening 103 for insertion and
removal of the light unit 20 and for the light output. The U-shaped
channel has an upper wall portion 101.9, and two J-shaped wall
portions 101.11 with inwardly directed curved lip portions 104 that
define a seat 101.16 for mounting and alignment of the SSL Light
Subassembly 20 insertion and removal of the light unit 20 and for
the U-shaped channel 101 for protection of the light unit 20. In
addition, the channel 101, provides one half of the alignment
mechanism 105, the full alignment system established when the strut
channel 101 is combined with the light unit 20 forming an SSL Light
Fixture Assembly 10. Referring to FIG. 1A, the light unit 20 may
have a maximum width W1, the channel opening 103 having a width of
W2, the light unit having a maximum height of H1. The height of the
light unit allowing insertion of the light unit into the channel
with a lateral side inserted first and the light unit rotated to
seat on the channel seat 101.16. In that the width of the end cap
are greater than the width of the channel opening as long as the
light unit is not rotated with respect to the channel, it remains
within the open interior 101.21.
[0070] In embodiments the maximum width of the light unit, which is
at the end cap is 1.375 inches. The max height is 0.75 inches.
[0071] The strut channel opening 103 for light output pattern 106
providing an optic control surface 107 to work in combination with
the light unit 20 optics system for redirecting of the subassembly
light output pattern 106, FIGS. 1A & 1B. The strut channel
structure, the U-shaped channel 101, FIGS. 1A-1B, 2 & 3 further
providing the mechanical integrity for structural ceiling grid
system 30 supporting installation of building system Mechanical,
Electrical and Plumbing components 305. The strut channel structure
101 FIG. 3 including features to provide for the necessary mounting
connection and routing of the system electrical power connection
and power supply such as fittings, electrical boxes 403 and other
similar components.
[0072] The SSL Fixture Assembly 10, FIG. 15A including one or more
SSL Light Subassemblies 20 with a remote LED driver 40 positioned
within a NEC approved standard J-Box 403 and flex conduit 401 power
supply to the J-box 403. The SSL Light Subassembly 20, FIGS. 15A
& 16 connected to the low power output of the remote LED driver
40 via a Class II wiring harness 411 with quick disconnect plug
assembly 410 connected to a wiring harness 411 with quick connect
receptacle 411.1 coming from the LED driver 40 and routed through
the strut channel 101 through a common strut channel electrical
fitting 403.1. The SSL Fixture Assembly 10, FIG. 15B including one
or more SSL Light Subassemblies 20, FIGS. 15A & 16 with a
remote longitudinal LED driver 41 mounted on a strut channel
raceway enclosure 404 fitted with end fittings and wired via flex
conduit 401 power supply to electrical knockouts 402.2 in the end
fittings. The SSL Light Subassemblies 20 connected to the low power
output of the remote Class II longitudinal LED Driver 41 via a
Class II wiring harness 410 with quick connect plug assembly 411
connected to a wiring harness with quick connect receptacle 411.1
coming from the LED driver 42 and routed through the internal or
external fittings 403.1 and or knockout 402 in the strut channel
raceway 101. The SSL Light Assembly 10, FIG. 15C including one or
more SSL Light Subassemblies 20 with a remote self-contained LED
driver 42 mounted on a structural beam 302.1 or other adjacent open
ceiling structure 302, FIG. 3. The SSL Light Subassemblies 20
connected to the low power output of the remote Class II
self-contained LED driver 42 and enclosure 404 and wired via flex
conduit 401 power supply to knockouts 422 in the line voltage
supply J-box 421 of the self-contained LED driver 42. The SSL Light
Subassemblies 20 connected to the low power output of the remote
Class II self-contained LED driver 42 via a Class II wiring harness
411 with quick connect plug assembly 411.1 connected to a wiring
harness with quick connect receptacle 410 coming from the
self-contained LED driver low voltage J-Box and routed through the
open ceiling structure through the top of the strut channel 101 via
a fitting 403.1 in an opening in the top of the strut channel
101.
[0073] The strut channel 101 structure FIG. 1A is typically
constructed of steel but may be made from various materials
including but not limited to aluminum, fiberglass, carbon graphite,
polyvinyl chloride (PVC), and other structural materials. The SSL
Light Subassembly 20 designed with an endcap 203 with a removable
alignment tab 203.3, FIG. 7 and an alignment notch 203.4 and when
inserted into a strut channel 101, FIG. 1B opening 102 in direct
contact with strut channel 101 vertical surface 104 as to produce a
gap 910 between housing 202 and strut channel 101 vertical support
structure 104, FIGS. 1B & 7. The SSL Light Subassembly 20, FIG.
7 having a housing 202 constructed of thermally conductive material
such as aluminum and at least one SSL Electrical Circuit 201
mounted to the housing 202 in such a manner as to provide for good
thermal conduction between the SSL Electrical Circuit 201 and the
housing 202. The housing 202 having a top surface 202.2 and side
vertical surfaces 202.1 with enough surface area as to provide
sufficient thermal dissipation 900, 901 & 903, FIG. 10 as to
maintain LED 201.1 Tc temperatures to achieve L70 50k hour
reliability performance regardless of the heat dissipation
properties of the common strut channel 101. In embodiments, thermal
dissipation of the SSL Light Subassembly 20 further enhanced
through the mounting positioning of the SSL Light Subassembly 20,
FIG. 10 positioned above the strut channel opening 103 in such a
manner as to leave a gap 910 between the housing 202 and the strut
channel 101. The opening 103 and gap 910 allowing free air flow 902
to enter the opening 103 and pass over the housing sides 202.1 and
housing top 202.2 heat convective surfaces providing a path for
heat dissipation 900, 901 & 903 to exit the SSL Light Assembly
10 through slot 108, FIG. 10. In one embodiment, a conductive path
from the SSL Light Subassembly 20 to the strut channel 101 can be
further conceived using direct contact with an inside surface of
the strut channel 101, custom mounting brackets or available gap
fillers as an alternate method of construction. These approaches
are generally less desirable due to tradeoffs in construction,
installation and thermal conduction to poor conductive strut
materials.
[0074] The strut channel structure 101 FIG. 3 including features to
provide for the necessary mounting, connection and routing of the
system electrical power connection and power supply such as
fittings, electrical boxes 403 and other similar components. The
strut channel 101, FIG. 1A further including features for assembly
and alignment of common mounting hardware 101.0 for insertion,
alignment and retention of the SSL Light Subassembly 20.
[0075] The SSL Light Subassembly 20, FIGS. 5A, 5B, & 5C
constructed with LED circuits 201. In embodiments, the LED circuit
201 is constructed with at least one LED 201.1 creating a
physically and electrically continuous LED circuit 220.1. In
additional embodiments, SSL Subassembly 20, FIG. 5B illustrates of
a polarity of LED circuits 201 each constructed with at least one
LED 201.1 and electrically connected between LED circuits 201
creating an electrically continuous, physically segmented LED
circuit 221.1 constructed within the SSL Light Subassembly 20. In
another embodiment, SSL Subassembly 20, FIG. 5C illustrates of an
LED circuit 201 constructed with individual spot LEDs 201.1 on a
continuous circuit 221.2.
[0076] The SSL Lighting Subassembly 20, FIGS. 5C & 7 further
includes optic system 204.2 for providing a variety of light output
patterns specific for use in low or high ceiling applications
typical in confined industrial spaces as well as general lighting
for hallways, mechanical or electrical utility rooms, and other
general lighting applications. The SSL Lighting Subassembly 20,
FIGS. 1B, 4 &7 comprises of a protective lens 204.1 providing
mechanical protection for the face of the electrical circuit 201,
LEDs 201.1, and optics 204.2. The SSL Lighting Subassembly 20,
FIGS. 1B & 4 further comprising of protective endcaps 203
providing protection for protective lens 204.1 face from damage
from edges from the strut channel 101 mechanical structure. The SSL
Light Subassembly 20, FIGS. 4 & 7 provide a seal 205.1 for a
variety of ingress protection levels preventing ingress of dust and
moisture. The SSL Light Subassembly 20, FIGS. 4 & 7 including a
seal 205.1 along tangential edges of the lens 204.1 and housing 202
as well as a seal 205.1 at the Endcaps 203 at each distal end of
the protective lens 204.1.
[0077] The SSL Lighting Subassembly 20, FIG. 7 in its embodiments
is constructed of a linear housing 202 with a top flat surface
202.2 and vertical walls 202.1 extending vertically from the flat
top surface 202.2. At the corners of the housing 202 where the flat
top 202.2 and vertical walls 202.1 intersect, the vertical wall
202.1 is recessed and rounded as to provide a vertical step from
the housing flat top 202.2 to the vertical wall surface 202.1. The
recessed feature 202.4 in the housing 202 is set in from a line
perpendicular to the flat housing top 202.2 and parallel to the
vertical wall surface 202.1 and is semicircular in form. The
recessed and semicircular feature 202.4 is duplicated in an offset
feature 203.5 in the endcap 203 and is the embodiment allowing for
installation clearance of the SSL Light Subassembly 20 within the
strut channel 101, FIG. 1A as part of final assembly of SSL Light
Fixture 10. The recessed and semicircular form 202.4 further
providing a location internal to the housing 202 corners adjacent
to the housing flat surface 202.2 for the formation of a uniform
wall thickness semicircular feature 202.5 partially open to the
inside of the housing and useful for Endcap attachment. The flat
housing top surface 202.2, FIG. 7 maintains a precise flatness and
parallelism to the endcap flat bottom surfaces 203.1 and alignment
removable tab 203.3 and alignment notches 203.4 thus providing
parallel alignment with the strut channel opening 103, FIG. 1B. The
vertical walls 202.1, FIG. 7 are generally non-flat providing
features running linearly along the vertical walls 202.1 for
handling during assembly of the SSL Light Subassembly 20 into the
strut channel 101 of the SSL Light Fixture 10, FIG. 1B. The
vertical walls further including features for retention of various
lens and optic components. Openings at the distal ends of the
vertical walls 202.1 provide features for protection to lenses
preventing damage to lenses and optics during installation into the
SSL Light Fixture. The embodiment including a pocket 202.7, FIG. 7
running linearly along the vertical walls 202.1 of the housing 202
from distal end to distal end and providing the function of
alignment of the lens 204.1 as well as containment of sealant 205.1
for sealing of the lens 204.1 or cover 204.3 to the housing
vertical walls 2021.
[0078] The SSL Lighting Subassembly 20, FIGS. 4, 7 & 8 utilizes
an Endcap 203 positioned at each distal end. The Endcap 203
providing features for optical alignment, subassembly installation,
sealing of the housing end from moisture and dust and protection
from mechanical damage during installation. The Endcap 203 in its
embodiment having a flat top 203.2 aligned parallel with the
housing flat top 202.2 and positioned slightly above the position
of the housing flat top 202.2 as to allow no portion of the housing
flat top 202.2 to extend beyond the Endcap flat top 203.2. The
Endcap 203, FIGS. 1A, 7 & 8 further having non-flat vertical
sides 203.5 providing finger grip locations along the outer
surfaces for holding of the SSL Light Subassembly 20 during
installation into the strut channel 101 of the SSL Light Fixture
10. The Endcaps 203, FIG. 8 having a horizontal shelf 203.6
extending beyond the inside vertical face 203.7 of the endcap 203
and precisely parallel to the desired position for the lens 204.1
in the housing 202. The gap above the horizontal shelf 203.6 being
the width of the lens 204.1 and/or cover 204.3 plus the additional
necessary gap for the adhesive and sealant used to create the seal
205.1. The horizontal shelf 203.6 aligned with the vertical wall
linear internal features for lens 204.1 and/or cover 204.3
installation, thus providing a feature for sealing the lens 204.1
to the Endcap 203 and housing 202. The endcaps 203, FIG. 8 having a
bottom flat face 203.1 which is precisely parallel to the plane
created in the housing flat top 202.2 and which extends beyond the
housing vertical wall ends 202.3, lens 204.1 and/or cover 204.3
linear features. The endcaps bottom flat 203.1 FIG. 8, in
combination with the endcap alignment tabs 203.3 and alignment
notch 203.4 at each distal end, in this embodiment, providing the
parallel alignment for the full SSL Light Subassembly 20 mounted
within the strut channel 101, FIG. 1B providing a consistent and
repeatable linear alignment system for the SSL Light Subassemblies
20 to the strut channel 101 longitudinal opening 103. The endcaps
203, FIG. 7 further having alignment notches 203.4 on the bottom
outside corners sized such as to align the geometric centerline of
the SSL electrical circuit 201 with the geometric centerline of the
structural channel opening 103. The endcap alignment notches 203.4,
FIG. 8 in certain embodiments of the present invention further
containing removable tabs 203.3 sized to adjust the height of the
SSL Light Subassembly 20 within the common structural channel
opening 103. The resulting change in height and relative position
between the SSL Light Subassembly 20 and structural channel opening
103 resulting in a change to the optical light output 106 pattern
from a medium 106, FIG. 12A to wide angle 106, FIG. 13. In the
embodiments, the angle of the optical light output pattern 106 may
be approximately 90 degrees to approximately 120 degrees.
[0079] Referring to FIGS. 7-9, in embodiments, the Endcaps 203 are
fastened to the SSL Light Subassembly 20 via mechanical fasteners
such as screws 204.0 extending into apertures in the distal face of
the endcaps 203 and extending through the respective wall and into
lobes or features 202.5 within the housing vertical walls 202.1 of
the housing 202. The Endcaps 203 further providing an opening for a
wiring cable 411 and associated strain relief 205 component FIGS. 4
& 9. The wiring cable 411, FIG. 4 extended beyond the SSL Light
Subassembly 20 and terminated with a luminaire electrical quick
connector 411.1, 411.2. On one distal end of the SSL Light
Subassembly 20, FIG. 4 the wiring cable 411 is terminated with an
electrical quick connect plug 411.1 or receptacle 411.2. On the
opposite distal end of the SSL Light Subassembly 20, the wiring
cable 411 is terminated with the mating electrical quick connector
(either receptacle 411.2 or plug 4111) or terminated with a
plug.
[0080] The SSL Light Subassemblies 20 can be connected end-to-end
within the SSL Light Fixture 10, FIG. 6A in succession thus
extending the overall lighted length of the fixture. The SSL Light
Subassemblies 20, FIG. 6A connected end-to-end with the wire cable
411 extending from the distal end of a first SSL Light Subassembly
20 and terminated with a wire quick connect receptacle 411.2
connected to a wire cable 411 extending from one distal end of a
second SSL Light Subassembly 20 and terminated with a wire quick
connect plug 411.1. The SSL Light Subassemblies 20 comprising of a
continuous SSL (LED) circuit 220.1. In another embodiment, the SSL
Light Subassemblies 20 comprising of a segmented SSL (LED) circuit
221.1, FIG. 6A. In another embodiment, the SSL Light Subassemblies
20 comprising of an individually spot (LED) circuit 221.2, FIG. 6A.
In a certain embodiment of the invention, the SSL Light
Subassemblies 20 are spaced along the SSL light fixture 10 and
strut channel 101 thus allowing for flexibility in the placement of
the light within a space FIG. 6A. A continuous linear SSL Light
Subassembly 20 can also be envisioned for applications where
maximum light output or visual aesthetics dictate such a solution
FIG. 6B. The SSL Light Subassemblies 20 can be continuous within
the SSL Light Fixture 10, FIG. 6B thus providing continuous light
over the lighted length of the fixture. The SSL Light Subassembly
20, FIG. 6B illustrating of a continuous SSL (LED) circuit 220.1
within the strut channel 101. In another embodiment, the SSL Light
Subassembly 20, FIG. 6B illustrating of a segmented SSL (LED)
circuit 221.1 within the strut channel 101. In another embodiment,
the SSL Light Subassembly 20, FIG. 6B illustrating of an
individually spot (LED) circuit 221.2 within the strut channel 101.
In certain embodiments the SSL Light Fixture 10 comprising of a
combined emitter configuration with individual optics 204.2, FIG.
5C to produce a multiplicity of individual Spot SSL Light
Subassemblies 20, FIGS. 6A & 6B for light output and alignment
with slot openings 108, FIG. 1B in the common strut channel
101.
[0081] The SSL Light Subassembly 20, FIGS. 4 & 7 having
sufficient mechanical structure between the housing 202, electrical
LED circuit 201, endcaps 203, seal 205.1 and optics structure 204.1
to allow retention of the SSL Light Subassembly 20 within the strut
channel structure 101. The SSL Light Fixture Subassembly 20
mechanically retained in the strut channel 101 utilizing
traditional strut channel fasteners 101.0, FIG. 2, including but
not limited to one or more spring loaded fasteners 101.0 with a
flat plate 101.01, FIG. 1B positioned against the internal flat
housing surface 101.1 with the spring compressed and pressed
against the SSL Light Subassembly 20 housing top flat surface
202.2, without damaging the SSL Light Subassembly 20 or rendering
the subassembly dysfunctional. The SSL Light Subassembly 20, FIG. 4
further having endcaps 203 at each distal end of the longitudinal
housing 202. The endcaps 203 having a width greater than the
opening 103 in the face of the strut channel 101, FIG. 1A as to
allow the upward J shaped support structure 104 and gravity to
retain the SSL Light Subassembly 20 within the Strut Channel 101.
The SSL Light Subassembly 20 being retained in a downward facing
orientation FIG. 11A such that the subassembly light output 106
exits the strut channel 101 opening 103 vertically downward and
angled outward. The light output 106 of the SSL Light Fixture 10
being determined as a function of the light output angle 106 as
achieved by the combination of the LED 201.1, FIG. 7, the secondary
optic 204.2, the optic lens 204.1 and the optic control surfaces
107, FIG. 12A & 13 or 109, FIG. 12B and the variable optic Y
position 800. The variable optic Y position 800 being determined by
the upward J shaped support structure 104 and the existence of the
removable alignment tab 203.3 or in the case of the removal of the
alignment tab 203.3, FIG. 13, the position of the alignment notch
203.4.
[0082] In other embodiments, the SSL Light Subassembly 20, FIGS. 4
& 7 having sufficient mechanical structure between the housing
202, electrical LED circuit 201, endcaps 203, sealing structure
205.1 and optics structure 204.1 to allow retention of the SSL
Light Subassembly 20 within the strut channel structure 101. The
SSL Light Fixture Subassembly 20 mechanically retained in the strut
channel 101 utilizing traditional strut channel fasteners 101.0,
FIG. 2, including but not limited to one or more spring loaded
fasteners 101.0 with a flat plate 101.01, FIG. 1B positioned
against the internal flat housing surface 101.1 with the spring
compressed and pressed against the SSL Light Subassembly 20 housing
top flat surface 202.2, without damaging the SSL Light Subassembly
20 or rendering the subassembly dysfunctional. The SSL Light
Subassembly 20, FIG. 4 further having endcaps 203 at each distal
end of the longitudinal housing 202. The endcaps 203 having a width
greater than the opening 103 in the face of the strut channel 101,
FIG. 1B as to allow the upward J shaped support structure 104 and
the pressure from the spring-loaded fastener 101.0 to retain the
SSL Light Subassembly 20 within the Strut Channel 101. The SSL
Light Subassembly 20 being retained in an upward facing orientation
FIG. 11B such that the subassembly light output 106 exits the strut
channel 101 opening 103 vertically upward and angled outward.
[0083] In other embodiments, the SSL Light Subassembly 20 FIGS. 4
& 7 having sufficient mechanical structure between the housing
202, electrical LED circuit 201, endcaps 203, sealing structure
205.1 and optics structure 204.1 to allow retention of the SSL
Light Subassembly 20 within the strut channel structure 101. The
SSL Light Fixture Subassembly 20 mechanically retained in the strut
channel 101 utilizing traditional strut channel fasteners 101.0,
FIG. 2, including but not limited to one or more spring loaded
fasteners 101.0 with a flat plate 101.01, FIG. 1B positioned
against the J shaped support structure 104 with the spring 101.02
compressed and pressed against the SSL Light Subassembly 20 housing
top flat surface 202.2, without damaging the SSL Light Subassembly
20 or rendering the subassembly dysfunctional. The SSL Light
Subassembly 20, FIG. 7 further having endcaps 203 with endcap flat
bottom 203.1 surfaces at each distal end of the longitudinal
housing 202. The endcap flat bottom 203.1 having a flat surface
with features to accommodate alignment with the strut channel 101
slotted openings 108 opposite the opening 103 in the face of the
strut channel 101 as to allow the downward J shaped support
structure 104 and the spring 101.02 force to retain the SSL Light
Subassembly 20 within the Strut Channel 101. The SSL Light
Subassembly 20 being retained in a downward facing orientation FIG.
11C such that the subassembly light output 106 exits the strut
channel 101 slotted openings 108 vertically downward and angled
outward.
[0084] In other embodiments, the SSL Light Subassembly 20 FIGS. 4
& 7 having sufficient mechanical structure between the housing
202, electrical LED circuit 201, endcaps 203, sealing structure
205.1 and optics structure 204.1 to allow retention of the SSL
Light Subassembly 20 within the strut channel structure 101. The
SSL Light Fixture Subassembly 20 mechanically retained in the strut
channel 101 utilizing traditional strut channel fasteners 101.0,
FIG. 2, including but not limited to one or more spring loaded
fasteners 101.0 with a flat plate 101.01, FIG. 1B positioned
against the J shaped support structure 104 with the spring 101.02
compressed and pressed against the SSL Light Subassembly 20 housing
top flat surface 202.2, without damaging the SSL Light Subassembly
20 or rendering the subassembly dysfunctional. The SSL Light
Subassembly 20, FIGS. 4 & 7 further having endcaps 203 with
endcap flat bottom 203.1 surfaces at each distal end of the
longitudinal housing 202, FIG. 2. The endcap flat bottom 203.1,
FIG. 11D having a flat surface with features to accommodate
alignment with the strut channel 101 slotted openings 108 opposite
the opening 103 in the face of the strut channel 101 as to allow
the upward J shaped support structure 104 and the spring 101.02
force to retain the SSL Light Subassembly 20 within the Strut
Channel 101. The SSL Light Subassembly 20 being retained in an
upward facing orientation FIG. 11D such that the subassembly light
output 106 exits the strut channel 101 slotted openings 108
vertically upward and angled outward.
[0085] In further embodiments, SSL Light Subassembly 20, FIG. 11E
retained within the Strut Channel 101 in a horizontal position with
the spring loaded fasteners 101.0 with a flat plate 101.01
positioned against the J shaped support structure 104 and as to
allow light output 106 at any other angle orientation between
horizontal or vertical with light output 106 exiting through either
the Strut Channel 101 opening 103 or slotted openings 108.
[0086] The SSL Lighting Subassembly 20, FIG. 1A is self-contained
within the physical geometry of the strut channel 101 allowing the
strut channel 101 to be fully utilized in the normal intended
function of a structural channel providing mechanical support for
building mechanical, electrical and plumbing system components.
Further, the SSL Lighting Subassembly 20, FIG. 1A is designed to
allow traditional mechanical attachment of the strut channel to the
building ceiling or ceiling structure without interference.
[0087] The SSL Light Subassembly 20, FIG. 1A allows for use of
either traditional electrical wiring with flex or rigid conduit and
conduit connectors designed for use with strut channel 101, or the
development of electrical wiring connectors specifically designed
to provide ease of assembly of the strut light fixture to the SSL
Light Subassembly 20.
[0088] The SSL light fixture assembly physical geometry FIG. 7 is
contained fully within traditional strut member types and
geometries FIG. 1A providing for design optimization of limited
physical space above and below the ceiling strut channel structure.
The SSL lighting subassembly FIG. 4 can be continuous or segmented
FIG. 6A allowing for continuous uniform lighting or lighting
segments in combination with other lighting or optics solutions
allowing for mixed lighting solutions. Mixed lighting solutions
including spotting, wall washing, wide or narrow angle options or
other combination lighting solutions.
[0089] The SSL Light Subassembly 20, FIG. 4 is of appropriate size
and of sufficient rigidity as to allow assembly into the common
structural channel FIG. 1A by means of direct insertion through the
continuous opening 103 in the structural channel 101 or by
insertion through an open end of the structural channel 101. The
SSL Light Subassembly 20 is sized such to fit through the opening
at an angle with the endcap flat surface 203.1, FIGS. 7 & 8
providing a smooth rigid surface for the SSL Light Subassembly 20
to slide along the inner wall 105 of the strut opening 103 while
the housing flat top 202.2 provides a flat surface for the SSL
Light Subassembly 20 to slide along the retention spring 101.02
retained inside the strut channel opening FIG. 1A. The SSL Light
Subassembly 20 housing 202 having a semicircular indented feature
202.4, FIG. 1B & 7 at the top corners and slightly inset from
the top flat surface 202.2 allowing the SSL Light Subassembly 20 to
rotate in the strut open pocket 102 without binding between the
inner walls of the strut channel 101 and the retainer spring.
Features on the vertical walls 202.1 of the housing extrusion 202
and endcaps 203, FIGS. 1B, 7 & 8 provide an increase finger
grip force and are beneficial to manipulating the SSL Light
Subassembly 20, FIGS. 4 & 16 through rotation when inserting
directly through the strut channel 101 opening 103 eliminating the
need for hand tools. Similarly, the features of endcap flat top
203.2 and endcap flat bottom 203.1 surfaces FIG. 7, and the endcap
203.5 and housing extrusion 202.1 finger grip features FIGS. 7
& 8, provide beneficial handling surfaces for removal of the
SSL Light Subassembly 20 from the strut channel 101, FIG. 1B for
servicing or realignment.
[0090] The SSL Light Subassembly 20 optics alignment system
providing for a variable light output half angle from narrow to
wide beam based on a combination of SSL Light Subassembly 20 and
strut channel opening relative position, and variable source,
internal optic or reflector, batwing or optic lens and strut
channel opening configuration. Certain embodiments of the invention
include but are not limited to a SSL Light Subassembly 20 and
Fixture Assembly with a 45-degree half angle light output with a
batwing pattern produced from an initial endcap position placing a
batwing lens at a depth behind the strut channel opening to cause a
portion of the light output pattern greater than 45-degree half
angle to be reflected and reintroduced into the 45-degree half
angle batwing pattern FIG. 16. The strut channel opening having a
reflective or baffled face construction on the opening vertical
legs to reflect the bulk of the light greater than 45 degree to 60
degrees at an angle placing the added reflected lighting into the
batwing pattern or alternatively, if baffled, added reflected
lighting directed back into the fixture FIG. 16.
[0091] Similarly, the same construction SSL Light Subassembly 20 or
Fixture Assembly with the strut channel opening features described
above to produce added reflected batwing or baffled lighting but
with the added feature of the removal of a tab extended within the
endcap alignment notches FIGS. 7 & 8. The removal of the tab
extensions repositioning the SSL Light Subassembly 20 within the
Fixture Assembly and relative to the strut channel opening such
that the previously added light or baffled light now passes through
the opening producing a 60-degree half angle light output within a
batwing pattern FIG. 13.
[0092] Embodiments herein include the method of retrofitting an
existing grid system 30, FIG. 3 of strut channels 101 where
individual strut channels 101 can be retrofitted with the SSL Light
Subassemblies 20, FIG. 4 by inserting at least one mounting
hardware 101.0 into the strut channel opening 103 followed by
inserting a SSL Light Subassemblies 20 directly through the opening
103 of the existing installed strut channels 101. The SSL Light
Subassembly 20 being rotated into the strut channel opening 103 and
retained between the hardware loaded spring 101.02 and the vertical
J shaped support structure 104, FIG. 1A. The SSL Light
Subassemblies 20 being electrically connected to power supply 40 in
a remote electrical j-box 403 via a supply wire harness 410, FIG.
15A routed through the open space between the ceiling structure 302
and the existing grid system 30, FIG. 3 with the strut channel 101
opening 102, FIG. 1A acting as an electrical raceway for containing
the wire cabling 411.
[0093] In another embodiment herein where the method of
retrofitting an existing grid system 30, FIG. 3 of strut channels
101 where a new individual strut channel 101 is assembled to the
existing grid systems 30 and oriented with a downward facing
opening 103. The newly add strut channel 101 fitted with the SSL
Light Subassemblies 20, FIG. 4 by inserting at least one mounting
hardware 101.0 into the strut channel opening 103 followed by
inserting a SSL Light Subassemblies 20 directly through the opening
103 of the existing installed strut channels 101. The SSL Light
Subassembly 20 being rotated into the strut channel opening 103 and
retained between the hardware loaded spring 101.02 and the vertical
J shaped support structure 104, FIG. 1A. The SSL Light
Subassemblies 20 being electrically connected to power supply 40 in
a remote electrical j-box 403 via a supply wire harness 410, FIG.
15A routed through the open space between the ceiling structure 302
and the existing grid system 30, FIG. 3 with the strut channel 101
opening 102, FIG. 1A acting as an electrical raceway for containing
the wire harness 411.
[0094] Dimensions disclosed herein are exemplary in embodiments.
The invention includes the components with given dimensions plus or
minus 5% of the given dimensions; in embodiments, plus or minus 10%
of the given dimensions. The light units may be 9'' to 96''. In an
embodiment the light units are 4 feet long with 45'' of lighted
length.
[0095] The invention is not restricted to the details of the
foregoing embodiment(s). The invention extends to any novel one, or
any novel combination, of the features disclosed in this
specification (including any incorporated by reference references,
any accompanying claims, abstract and drawings), or to any novel
one, or any novel combination, of the steps of any method or
process so disclosed The above references in all sections of this
application are herein incorporated by references in their entirety
for all purposes.
[0096] Although specific examples have been illustrated and
described herein, it will be appreciated by those of ordinary skill
in the art that any arrangement calculated to achieve the same
purpose could be substituted for the specific examples shown. This
application is intended to cover adaptations or variations of the
present subject matter. Therefore, it is intended that the
invention be defined by the attached claims and their legal
equivalents, as well as the following illustrative aspects. The
above described aspects embodiments of the invention are merely
descriptive of its principles and are not to be considered
limiting. Further modifications of the invention herein disclosed
will occur to those skilled in the respective arts and all such
modifications are deemed to be within the scope of the
invention.
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